Fiber optic hermetic bulkhead penetrator feedthrough module and method of fabricating same

Abstract

A hermetically sealed fiber optic feedthrough module which comprises a metal or other rigid material connector feedthrough or sleeve feedthrough with a single fiber optic member or with a multitude of optical fibers extending through and protruding out of either side of the connector feedthrough or sleeve feedthrough and a pressure-blocking sealant material of polycrystalline which surrounds the fiber optic member(s) and provides a seal between the fiber optic member(s) and the inside surface of the connector or sleeve feedthrough. The feedthrough module is made by positioning the fiber optic member(s) through the connector or sleeve feedthrough and applying the polycrystalline sealant material between the fiber optic member(s) and the connector or sleeve feedthrough inside diameter to fill all voids between the fiber optic member(s) and connector or sleeve feedthrough. Heat is then applied to "set" the polycrystalline or other material which provides hermetically sealed intimate contact between the various feedthrough module components.

What is claimed is: 
     
       1. A hermetic pressure differential and temperature differential feedthrough system comprising: a signal transmitting optical fiber or plurality of optical fibers; a hermetic sealing material providing an extremely high fluid or gas differential pressure and temperature differential seal; a feedthrough housing of suitable material to provide a substantial bond between said housing and said hermetic sealing material; said signal transmitting optical fibers which are suitably cleaned and may be stripped of buffer coatings to provide a substantial bond between said fibers and said hermetic sealing material; said signal transmitting optical fibers passing through said feedthrough housing which may have a connector interface on either or both sides of said feedthrough comprised of fibers hermetically sealed within a fiber optic terminus or other system requiring interfaces and requiring interconnecting means to couple the feedthrough housing to a connector half; said bonds between said hermetic sealing material and said signal transmitting optical fiber, between said hermetic sealing material and said fiber optic termini, and between said sealing material and said housing are provided by mechanical, chemical or environmental means.   
     
     
       2. The feedthrough according to claim 1 wherein said signal transmitting optical fibers of suitable material which are suitably cleaned and may be stripped of buffer coatings to provide a substantial bond between said fiber and said hermetic sealing material resulting in a pressure seal capable of withstanding in excess of 30,000 psi. 
     
     
       3. The feedthrough according to claim 2 with hermetically coated signal transmitting optical fibers to provide a substantial bond between said fiber and said hermetic sealing material. 
     
     
       4. The feedthrough according to claim 3 with bare clad signal transmitting optical fibers which are suitably cleaned and stripped of buffer coatings and having suitable cladding material which provides a substantial bond between said fiber and said hermetic sealing material. 
     
     
       5. The feedthrough according to claim 1 wherein said hermetic sealing material consisting of an optimum combination or combinations of specific compounds providing a substantial bond between said components of the feedthrough providing a pressure seal capable of withstanding in excess of $30,000. 
     
     
       6. The feedthrough according to claim 2 wherein the hermetic sealing material maintains said pressure block while exposed to heat and cold within a temperature range from -200° C. to in-excess of +200° C. 
     
     
       7. The feedthrough according to claim 6 wherein the hermetic consists of a polycrystalline compound. 
     
     
       8. The feedthrough according to any of claims 2, 3, 4, 5, 6, or 7 wherein the feedthrough housing is suitable for bulkhead penetration use, which provides either a fiber or plurality of fibers passing through said feedthrough housing or a connector/termini interface on either or both sides of the bulkhead. 
     
     
       9. The feedthrough according to claim 8 wherein the feedthrough housing is constructed of a suitable metallic substance which provides a substantial bond between said housing and the chosen hermetic sealing material. 
     
     
       10. The feedthrough according to claim 8 wherein the feedthrough housing is constructed of a ceramic or glass material which provides a substantial bond between said housing and the chosen hermetic sealing material. 
     
     
       11. The feedthrough according to claim 8 wherein the feedthrough housing is constructed of a composite material which provides a substantial bond between said housing and the chosen hermetic sealing material. 
     
     
       12. The feedthrough according to claim 8 comprising one or more of the following features to allow said feedthrough to be attached to a bulkhead; a flange arrangement which allows it to be bolted to the bulkhead, threads on the outside edge to allow a flange nut to secure said feedthrough to the bulkhead, weldment of said feedthrough housing to the bulkhead or other suitable attachment configuration to meet the system requirements. 
     
     
       13. The feedthrough according to claim 1 wherein the feedthrough style employs one side with continuous exiting fibers and one side with features to allow addition of an accessory backshell to provide support, strain relief and protection of the signal transmitting optical fibers. 
     
     
       14. The feedthroughs according to claim 1 with provision for addition of an accessory backshell on both sides of the feedthrough to provide support, strain relief and protection of the signal transmitting optical fibers. 
     
     
       15. The feedthrough according to claim 1 with provision on one side of the feedthrough for a fiber terminating in the rear of a pin terminus and the other side of the feedthrough with provision for a connector mating mechanism and the single-ended pin termini positioned within the connector half for mating to socket termini, the connector configuration may employ any style of connector mechanism. 
     
     
       16. The feedthrough according to claim 15 with provision on one side of the feedthrough for connector mating and provision on the other side of the feedthrough for continuous fiber with addition of an accessory backshell to provide support, strain relief and protection of the signal transmitting optical fibers, the connector configuration may employ any style of connector mechanism. 
     
     
       17. A hermetic pressure differential and temperature differential feedthrough system comprising: a signal transmitting optical fiber or plurality of optical fibers; an insert sleeve; a hermetic sealing material providing an extremely high fluid or gas differential pressure and temperature differential seal; a feedthrough housing of suitable material to provide a substantial bond between said housing and said hermetic sealing material; said insert sleeve providing a substantial bond between said sleeve and said hermetic sealing material; said signal transmitting optical fibers which are suitably cleaned and may be stripped of buffer coatings to provide a substantial bond between said fibers and said hermetic sealing material; said signal transmitting optical fibers passing through said feedthrough housing which may have a connector interface on either or both sides of said feedthrough comprised of fibers hermetically sealed within a fiber optic terminus or other system requiring interfaces and requiring interconnecting means to couple the feedthrough housing to a connector half; said bonds between said hermetic sealing material and said signal transmitting optical fiber, between said hermetic sealing material and said housing, between said hermetic sealing material and said fiber optic termini, and between said hermetic sealing material and said insert sleeve provided by mechanical, chemical or environmental means.   
     
     
       18. The feedthrough according to claim 17 wherein said signal transmitting optical fibers which are suitably cleaned and may be stripped of buffer coatings to provide a substantial bond between said fibers and said hermetic sealing material resulting in a pressure seal capable of withstanding in excess of 30,000 psi. 
     
     
       19. The feedthrough according to claim 18 with hermetically coated signal transmitting optical fibers providing a substantial bond between said fibers and said hermetic sealing material. 
     
     
       20. The feedthrough according to claim 19 with clad signal transmitting optical fibers which are suitable cleaned and may be stripped of buffer coatings providing a substantial bond between said fibers and said hermetic sealing material. 
     
     
       21. The feedthrough according to claim 17 wherein said hermetic sealing material consists of an optimum combination or combinations of specific compounds providing a substantial bond between said sealing material and said other components of the feedthrough providing a pressure seal capable of withstanding in excess of 30,000 psi. 
     
     
       22. The feedthrough according to any of claims 17 or 21 wherein said insert sleeve is constructed of a suitable metallic substance providing a substantial bond between said insert sleeve and said hermetic sealing material. 
     
     
       23. The feedthrough according to any of claims 17 or 21 wherein said insert sleeve is constructed of a ceramic or glass material providing a substantial bond between said insert sleeve and said hermetic sealing material. 
     
     
       24. The feedthrough according to any of claims 17 or 21 wherein said insert sleeve is constructed of a composite material providing a substantial bond between said insert sleeve and said hermetic sealing material. 
     
     
       25. The feedthrough according to claim 18 wherein said hermetic sealing material maintains said pressure seal while exposed within a temperature range from -200° C. to in excess of +200° C. 
     
     
       26. The feedthrough according to claim 25 wherein said the hermetic sealing material shall consist of a polycrystalline material. 
     
     
       27. The feedthrough according to any of claims 18, 19, 20, 21, 25 or 26 wherein said feedthrough is suitable for bulkhead penetration use, which provides either a fiber or plurality of fibers passing through said feedthrough housing or provides a connector terminus or termini interface on either or both sides of the bulkhead. 
     
     
       28. The feedthrough according to claim 27 wherein said feedthrough housing is constructed of a metallic substance suitable for providing a substantial bond between said housing and said hermetic sealing material. 
     
     
       29. The feedthrough according to claim 27 wherein said feedthrough housing is constructed of a ceramic or glass material suitable providing a substantial bond between said housing and said hermetic sealing material. 
     
     
       30. The feedthrough according to claim 27 wherein the feedthrough housing is constructed of a composite material providing a substantial bond between said housing and said hermetic sealing material. 
     
     
       31. The feedthrough according to claim 27 comprising any of the following features enabling said feedthrough to be attached with hermetic seal capability to a bulkhead; a flange arrangement which allows it to be bolted to the bulkhead,   threads concentric on the outside surface allowing a flange nut to secure said feedthrough with a pressure seal to the bulkhead,   weldment of said feedthrough housing to the bulkhead or   other attachment means of a pressure sealing and mechanical attaching configuration.